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3D Jellies & Gummies

Weighs and mixes up to 16 dry and liquid confectionery ingredients into a homogeneous slurry. Individual ingredients are fed via a weigh hopper into the mixer and mixed during the fill cycle to produce a consistent slurry. Batches are fed from the Autofeed mixing tank to two reservoir tanks to facilitate a continuous feed to the cooker.

Incorporates colours and flavours into the cooked syrup via a gravity split feed system. Each colouring and flavouring system is specified to match the level of automation required by the customer and the characteristics of the depositing system.

Fully three dimensional jellies are a high-value, high-margin segment of the fast-growing jelly market. Depositing is the only method capable of manufacturing these complex shapes at high outputs and with low production costs.

Unique market opportunities

3D jellies can be made in one or two colours; with stripes and layers; with solid or soft centre-fills; and with inclusions such as real fruit pieces. Product possibilities include balls or spheres, animals and cartoon characters, and fruit shapes such as raspberries, strawberries and pears.

There is great potential for character merchandising linked to television and films. Because of the importance of speed-to-market in this short-term environment, the process of developing a new product ready for manufacture has been compressed. New designs can be visualised and models made very quickly using the latest 3D CAD and 3D printing techniques to make test moulds for trials.

Rapid low-cost product changes

The process uses quick-setting jelly formulations, typically pectin- or carrageenan-based. To ensure fast changeover between production runs, the mould system uses a new carrier design, with clip-in moulds that allow rapid, low-cost product change by replacing just the moulds rather than the complete carrier system. This widens the range of products that a single line can produce; this versatility may be enhanced by the ability to deposit multiple shapes in different colours simultaneously.

Cost-effective, high quality products

The accuracy and hygiene of modern cooking and depositing techniques ensures that products made using Baker Perkins' ServoForm™ Jelly process benefit from exceptional weight and dimensional accuracy, with no shrinkage, and enhanced definition for intricate product shapes.

Accurate positioning of the mould under the depositor nozzle and of the stream of syrup into the mould ensure consistent mould fill with no waste and allow the mould opening to be minimised, achieving a more realistic 3D shape.

Air ejection from the mould is more hygienic than brush-based ejection systems, and ensures the product is undamaged. The products are deposited at final solids so no drying is required.

As an alternative to starch moguls, starchless depositing is significantly more cost-effective in every aspect: capital cost, floor space, energy consumption, labour and consumables. It is also completely hygienic, with a fully automatic wash-through function, non-contact ejection system and no recycling of starch.